How to Fit a Turbocharger

Please read this document before fitting your Turbo

FAILURE TO FOLLOW INSTRUCTIONS WILL VOID YOUR GUARANTEE

Correctly installed turbocharger make significant contributions to performance, fuel efficiency and emissions control, but incorrect fitting can have serious, potentially harmful consequences, including ECU conflict and major engine damage.

1) Why Turbos Fail - Diagnosis

Investigate cause of original turbo failure before fitting replacement. Most turbo failures are due to: Oil Starvation/Contamination, ECU failure, Air leaks, Over speeding turbo, or Foreign matter entering compressor housing or Breather problems.

2) Rectify Malfunction

Upon completion of diagnosis and conclusion of malfunction or component failure, either you must rectify the malfunction/replace the failed components with new components (retain proof of purchase, ie receipts). Check for foreign particles. All BEFORE you fit the new turbo.

3) Replace Components

Before fitting your new/reconditioned Turboservce24 Ltd turbocharger, you must Replace Components listed below, with new components and again RETAIN all receipts/proof of purchase.

• OIL FEED PIPE (from engine to top of turbo), replace banjo bolts
• NEW OIL PUMP (Peugeot/Citroen/Ford/Mazda/Volvo 1.6 DIESEL)
• Oil + oil filter (correct grade as per manufacturers recommendation)
• Air filter
• Gaskets + washers, O rings
• Particulate filter and liquid level sensor topped up with correct spec of fluid

4) Clean or Replace

• Air box and air intake hose to turbo (Pressure Test)
• Oil cooler/inter cooler/hose, from turbo to inter cooler (damage or air leak). Get Pressure Tested.
• E.G.R. VALVE - Check correct operation, clean or replace if necessary
• Breather system, cam cover (rocker cover) - check for blockage
• Replace Turbo oil drain hose (check clear/ check no damage to pipe)
• Clean Inlet/exhaust manifolds, check for carbon deposits/cracks/clean head faces/replace gaskets
• Ensure the exhaust and/or catalytic converter/diesel particulate filter (DPF) are not fully or partly blocked

5) Before Fitting a Turbo:

• Check no debris enters turbo
• Check all gaskets fit with gas tight seal
• Flush Engine

6) Fit and Test Turbo

• Check OIL PRESSURE is within Manufacturers Tolerances
• Do Not Use Jointing Compound on ANY part of the Turbo
• Fill turbo inlet with oil and prime turbo manually
• Before fitting turbo, immobilise engine, (eg: remove fuel pump fuse)
• Manually crank engine until oil flows steadily out of turbo oil feed hose
• After fitting turbo, manually crank engine for 30 sec until oil flows from turbo oil return pipe
• Start engine and allow to idle for 3-5 mins before driving (do not let engine idle unnecessarily)
• Check for Oil/Gasket/Air Leaks, all obvious locations on engine
• Plug into diagnostic machine to check for any fault codes (rectify/repair as per diagnosis, before road test). Check boost pressure
• Must get re test done after 50-60 miles & replace any item which re-appears in diagnosis

These are few of the steps that experts take in to consideration fitting a new turbo - remember engine and/or turbocharger damage can be caused through incorrect installation, so always consult a professional.